Ford F6TZ-9350-A Fuel Pump Assembly

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Three electric fuel pump configurations exist for F-series and Bronco vehicles: carbureted 7.5L engines with the "Hot Fuel" option utilize an in-tank low-pressure fuel pump, controlled by a fuel pump relay triggered by an engine oil pressure switch and powered through an inertia switch; early EFI models (pre-1990) employ a low-pressure in-tank pump and an externally mounted high-pressure pump, regulated by a pressure regulator on the fuel rail; later models (1990 and onward) feature an in-tank fuel delivery module (FDM) housing a high-pressure fuel pump, venturi jet pump, relief check valves, and shuttle selector valve. Operational checks involve verifying pump operation during startup and continuous running, addressing issues through diagnostic procedures, circuit checks, and pump replacements as necessary. For EFI models, additional engine off and running pressure checks, static pressure leakage checks, and in-tank low-pressure pump checks are performed to ensure proper fuel system function.

The fuel pump is positioned on the left front side of the block or timing chain cover, operated by an eccentric cam on the camshaft, inducing the up and down movement of the rocker arm. The rocker arm, in turn, pulls the internal diaphragm against its spring, drawing fuel into the pump chamber, which is then pressurized for exit, with check valves preventing reverse flow. Issues in the fuel pump can result in insufficient fuel delivery or a lean condition in the engine. Before removing a potentially defective fuel pump, ensure the tank has fuel, the fuel filter is not plugged, and inspect mechanical connections and hoses for leaks. The operational check involves capacity and pressure tests. For the capacity test, the air cleaner assembly is removed, the fuel line disconnected at the fuel filter inlet, and the fuel pump output assessed. If the output is low, a remote fuel supply test is conducted, and if still inadequate, the fuel pump, camshaft lobe, and operating lever are inspected. The pressure test involves connecting a fuel pressure gauge, starting the engine, and checking pressure after ten seconds. If pressure is insufficient, a new fuel pump is recommended. Reconnect the fuel line and install the air cleaner after completing the tests.

For the removal of the mechanical fuel pump on carbureted models, begin by disconnecting the battery cable and placing a drain pan underneath. Remove the outlet pipe and inlet line at the fuel pump, plugging the end of the line to prevent leakage. Take out the bolts securing the fuel pump to the timing cover or engine block, and remove the pump along with the gasket. Clean the mating surfaces thoroughly. Installation involves placing a new gasket coated with RTV sealant, lubricating the fuel pump rocker arm, positioning the pump against the block or timing cover, and tightening the retaining bolts. Connect the inlet and outlet lines, reconnect the battery cable, and start the engine, checking for leaks.For the electric fuel pump on externally mounted, fuel-injected models from 1987 to 1989, relieve fuel system pressure and disconnect the battery cable. If necessary, raise the vehicle and locate the fuel pump along the inboard side of the left-side frame rail. Disconnect the electrical connector and fuel lines, remove the mounting bolts, and take out the pump. During installation, reset the inertia switch and ensure proper installation of pump fittings, wiring harness boots, and isolator. Reconnect the battery cable, start the vehicle, and check for proper pump operation and leaks.For the in-tank electric fuel pump, relieve fuel system pressure and remove the fuel tank. On plastic tanks, unscrew the locking ring and remove the pump/sending unit, while on metal tanks, tap the locking ring counterclockwise and remove the pump/sending unit. Installation involves coating the new sealing ring with grease, avoiding filter damage, aligning tabs in the pump/sending unit with tank flange slots, and reconnecting the battery cable. Start the vehicle and check for proper pump operation and leaks.